Independent foam spring mattress

ABSTRACT

Embodiments of an independent foam spring mattress are disclosed. The independent foam spring mattress typically includes a sculpted layer of foam which has a plurality of foam pillars separated by a grid pattern of grooves. These foam pillars may be positioned and oriented in the mattress with respect to one or more additional foam layers to serve as independent foam springs. Accordingly, disclosed mattress embodiments typically would be all-foam mattresses, without any metal springs.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a non-provisional of and claims benefit under 35 U.S.C. §119 to co-pending U.S. Provisional Patent Application Ser. No. 61/977,989, filed on Apr. 10, 2014, and entitled “Independent Foam Spring Mattress”, which is hereby incorporated by reference for all purposes as if reproduced in its entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE TO A MICROFICHE APPENDIX

Not applicable.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.

FIG. 1A illustrates an exploded perspective view of the foam layers of an embodiment of an independent foam spring mattress (in which the sculpted foam layer is the uppermost foam layer and is oriented with pillars facing downward to provide a flat sleep surface). FIG. 1Aa illustrates a side view of the assembled foam layers of the mattress embodiment of FIG. 1A.

FIG. 1B illustrates an exploded cut-away (e.g. cross-section) perspective view of the foam layers of an embodiment similar to that of FIG. 1A (in which the sculpted foam layer is the uppermost foam layer and is oriented downward), but the middle foam layer has vertical pin holes extending from its upper surface to its lower surface through the height/thickness of the middle foam layer. FIG. 1Ba illustrates a side cut-away (e.g. cross-section) view of the assembled foam layers of the mattress embodiment of FIG. 1B.

FIG. 1C illustrates an exploded cut-away (e.g. cross-section) perspective view of the foam layers of an embodiment similar to that of FIG. 1A (in which the sculpted foam layer is the uppermost foam layer and is oriented downward), but the middle foam layer is channeled (for example, with channels running across its bottom/lower surface). FIG. 1Ca illustrates a side cut-away view of the assembled foam layers of the mattress embodiment of FIG. 1C.

FIG. 1D illustrates an exploded cut-away (e.g. cross-section) perspective view of the foam layers of an embodiment similar to that of FIG. 1A (in which the sculpted layer of foam is oriented downward), except that the sculpted layer of foam is not the upper most layer of (support) foam, but is located beneath a top/sleep surface layer of foam (such that the sculpted layer is the middle/inner foam layer, sandwiched between a top/upper/surface layer of foam and a lower/bottom/base layer of foam). FIG. 1Da illustrates a side cut-away view of the assembled foam layers of the mattress embodiment of FIG. 1D.

FIG. 1E illustrates an assembled side cut-away view is the foam layers of a mattress embodiment similar to FIG. 1A or FIG. 1Da, in which the sculpted layer is one of four foam layers, the sculpted layer faces downward, and the sculpted layer is located below a sleep surface foam layer and above a support layer an a base layer.

FIG. 2A illustrates an exploded perspective view of the foam layers of another embodiment of an independent foam spring mattress (in which the sculpted foam layer is not the top layer and is oriented with pillars facing upward).

FIG. 2B illustrates an exploded cut-away (e.g. cross-section) perspective view of the embodiment of FIG. 2A, in which the sculpted foam layer is oriented (with pillars) facing upward and is sandwiched between a top/upper/sleep surface layer of foam and a lower/bottom/base layer of foam. FIG. 2Ba illustrates a side cut-away view of the assembled foam layers of the mattress embodiment of FIG. 2B.

FIG. 2C illustrates a side cut-away (e.g. cross-section) view of the assembled foam layers of a mattress embodiment similar to that of FIG. 2Ba, in which the surface layer of foam comprises vertical pin holes.

FIG. 2D illustrates a side cut-away view of the assembled foam layers of a mattress embodiment similar to that of FIG. 2A, but having two layers of foam (e.g. a sleep surface layer and a support layer) above the sculpted layer of foam.

FIG. 3 illustrates a top plan view of the pillar portion side (e.g. sculpted surface) of an embodiment of the sculpted foam layer of the independent foam spring mattress of FIGS. 1A-2B.

FIG. 4 illustrates a perspective view of an exemplary non-sculpted layer of foam (for example, the middle layer of FIG. 1B or the top/upper layer of FIG. 2C) having a plurality of pin holes extending through its thickness/height.

FIG. 5 illustrates an exemplary method of assembly/formation for a mattress embodiment similar to that of FIG. 1A.

DETAILED DESCRIPTION

It should be understood at the outset that although illustrative implementations of one or more embodiments are illustrated below, the disclosed systems and methods may be implemented using any number of techniques, whether currently known or not yet in existence. The disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, but may be modified within the scope of the appended claims along with their full scope of equivalents.

The following brief definition of terms shall apply throughout the application:

The term “comprising” means including but not limited to, and should be interpreted in the manner it is typically used in the patent context.

The term “foam” means a material in a lightweight cellular form, for example resulting from introduction of gas bubbles during manufacture to produce a consistent cell structure, and/or any of various light, porous, semirigid or spongy materials or cellular solids, usually the solidified form of a liquid full of gas bubbles, which may be used as a building material or for shock absorption, and includes open cell foams such as polyurethane foam, latex, memory foam, specialty memory foam, gel memory foam, gel latex foam or other gel foams, etc.;

The term “IFD” means indentation force deflection, and describes a well-known measurement system for foam firmness;

Directions, such as up (e.g. upward) and/or down (e.g. downward), typically are intended to be based on the mattress in its normal sleeping position as understood by persons of skill; for example, the upper surface of the mattress might face the ceiling, while the bottom surface of the mattress might face the floor or ground;

The phrases “in one embodiment,” “according to one embodiment,” and the like generally mean that the particular feature, structure or characteristic following the phrase may be included in at least one embodiment of the present invention, and may be included in more than one embodiment of the present invention (importantly, such phrases do not necessarily refer to the same embodiment);

If the specification describes something as “exemplary” or as an “example,” it should be understood that refers to a non-exclusive example:

The terms “about” or “approximately” or the like, when used with a number may mean that specific number, or alternatively, a range in proximity to the specific number, as understood by persons of skill in the art field (for example, +/−10%); and

If the specification states a component or feature “may,” “can,” “could”, “should,” “would,” “preferably,” “possibly,” “typically,” “optionally,” “for example,” “often,” or “might” (or other such language) be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic. Such component or feature may be optionally included in some embodiments, or it may be excluded.

Disclosed embodiments relate to mattresses (for example, sized conventionally such as twin, full, queen, king, etc.) having a layer of foam with a sculpted surface (e.g. a contour cut layer of foam). Typically, such mattresses would be spring-free (e.g. all-foam, without any springs), and the sculpted foam layer might effectively replace the support functionality of the springs while also often providing added benefits. For example, a sculpted foam surface (e.g. foam pillars) may provide more flexibility in adjusting to various body contours than metal springs, and therefore may be more effective in reducing pressure points against the human body than traditional metal springs in conventional mattresses. More specifically, the layer of foam with a sculpted surface would include a plurality of foam pillars (or blocks), each of which is freestanding (e.g. independent) with respect to the other pillars, but all of which are joined together into a single integral base (which typically has a flat exterior surface). So, the base portion of the pillars are all joined together (e.g. a common base), while the remaining freestanding portion of the layer of foam comprise a plurality of independent pillars separated from one another by a gap or groove on all sides. Stated another way, the sculpted layer of foam may comprise a base portion (which typically is a uniform flat sheet of foam) and a pillar portion (which typically comprises a plurality of independent pillars or blocks of foam, each of which is completely separate from the other pillars), with the pillar portion being securely attached to a surface of the base portion (so in effect the pillars project out from the flat base portion). Thus, the sculpted surface of the sculpted layer of foam would typically be the distal surface of the pillars (or pillar portion). Typically, the sculpted layer of foam is formed by cutting a pattern of grooves in one surface (which would then become the sculpted surface) of an initially uniform (e.g. flat sheet with constant thickness) sheet of foam, thereby forming a plurality of foam pillars which extend out from the base portion (with the pillar portion and the base portion integrally forming a single layer of foam having different shapes/characteristics on opposing sides). Thus, the sculpted layer of foam might also be termed a contour cut layer of foam in some embodiments (since in many embodiments the layer of foam is sculpted via cutting, for example contour cutting). In other embodiments, it may be possible to form the sculpted layer of foam by molding (with the mold forming the pillar portion projecting outward from the base portion). Typically, the substantially one entire surface of the sculpted foam layer (e.g. the entire sculpted surface) would be entirely comprised of such pillars (e.g. substantially the entire sculpted surface of the sculpted foam layer would be formed of pillars), although in other embodiments the sculpted surface might have pillars only on a portion of the sculpted surface. Such exemplary mattresses typically would also comprise at least one additional layer of foam (for example, at least one additional layer of foam underlying the sculpted layer as a base). For example, many embodiments might comprise a sculpted foam layer and at least two other layers of foam (e.g. at least three total foam layers, counting the sculpted foam layer, with most embodiments having between three and four total foam layers). So, exemplary mattresses would typically comprise a sculpted layer of foam and one or more other foam layers, with the position of the sculpted foam layer (relative to the other layers) and the orientation of the sculpted foam layer (e.g. with sculpted surface facing up or down) varying based on the details of the specific embodiment (although typically there would be at least one layer underlying the sculpted foam layer and a flat upper sleep surface for the mattress). And typically, all such foam layers would be adhered into an integrated whole (e.g. laminated) and/or enclosed/encased in a cover, thereby forming an integrated mattress.

Typically, the sculpted layer of foam would have a plurality of foam pillars forming the sculpted surface, and the pillars would be configured within the sculpted foam layer and the mattress as a whole to essentially be limited to movement only (or in some embodiment, primarily) in the vertical direction (e.g. without any horizontal/sideways movement of the pillars during use of the mattress). In other words, the configuration of the foam layers of the mattress (for example, with the layers placed in contact in such a way as to minimize shear or torsion in the pillars during construction (e.g. essentially placing the pillars only in compression) and with the layers laminated together) would typically ensure that compression on the top (e.g. sleep surface) of the mattress would be transmitted to the foam pillars entirely as a vertical (e.g. compression) force (without, for example, introducing any horizontal, shear, or torsion forces to the foam pillars) for each affected foam pillar. Additionally, each pillar of foam in the sculpted layer would be configured for essentially independent movement (e.g. each pillar moves independent of the other, surrounding/proximate pillars). This independence might arise due to the contour cuts (e.g. grooves/gaps) separating the foam pillars and/or the fact that the base of the foam pillars would be linked by conformable foam (e.g. in the form of an integrated base of foam linking all pillars together). So, embodiments might have pillars of the sculpted foam layer configured for essentially independent movement and/or essentially only vertical movement during usage of the mattress (e.g. by a user lying atop the mattress). Typical embodiments might have the pillars configured for independent movement essentially only in the vertical direction. For example, each foam pillar might be operable to move vertically without substantially imparting any vertical movement to surrounding/proximate foam pillars in the sculpted foam layer. Thus, movement by one foam pillar typically might not impart any movement to other foam pillars in proximity within the sculpted foam layer (such that each pillar movement would independently relate to its own loading from the sleep surface above). So, each foam pillar of an exemplary sculpted foam layer in a disclosed mattress embodiment may be operable to only (or in some embodiments primarily) carry/support compression forces from directly above the foam pillar. Of course, Applicant does not intend to be bound by theory, but rather simply notes that the presently disclosed embodiments may perform/operate differently and/or better. Such configuration of the sculpted foam layer (with regard to movement) may be quite different from the typical movement allowed/provided by conventional metal springs (e.g. coil springs in a mattress). Conventional coil spring mattresses have a series of springs which typically are linked by wire across their top surfaces. Thus, the coil springs do not move independently (e.g. movement by one coil spring necessarily affects the surrounding coil springs due to the rigid nature of the linking wire frame) and the linking wire frame at the top of the coil springs may typically introduce non-vertical (e.g. non-compression) forces into the springs (such that the coil springs may flex and move horizontally and/or torsionally, for example, in response to a user atop the mattress sleep surface). Thus, the disclosed embodiments (with foam pillars in a spring-less mattress) may perform quite differently in operation than a conventional spring mattress.

It should also be noted that a typical disclosed mattress embodiment would comprise three or more foam layers (e.g. stacked atop one another and optionally adhered to one another (e.g. laminated)). In such a configuration, the top foam layer would be the sleep surface layer (with a flat upper sleep surface), the middle layer(s) would be support layer(s), and the bottom layer of foam would be the base layer. Typically, the sleep surface layer of foam would be the least firm (e.g. softest) foam layer, the bottom layer of foam would be the firmest foam layer, and the middle layer(s) of foam would have firmness between that of the top and bottom layers. So for example, the firmness of the layers of foam in embodiments might vary from least firm (e.g. softest) to most firm when moving from top to bottom of the mattress. By way of illustrative example, the sleep surface layer IFD (or effective IFD if there are pin holes, for example) might range from 10-20, 12-17, or 12-15; the middle support layer(s) IFD (or effective IFD if there are pin holes, channels, or convolutions, for example) might range from 18-25 (so long as it is higher/firmer than the IFD for the sleep surface layer); and the bottom/base layer IFD might range from 28-35, 30-35, or 30-33. So for example, in a three layer all-foam mattress, the sleep surface layer (which may or may not be the sculpted foam layer, depending on configuration of the mattress) might have an IFD of about 12, the middle (support) layer (which may or may not be the sculpted foam layer, depending on the configuration of the mattress) might have an IFD of about 18 or about 25 (depending on the embodiment), and the base layer might have an IFD of about 30. In another exemplary all-foam mattress having four layers, the sleep surface layer might have an IFD of 12, the upper support layer might have an IFD of 18, the lower support layer might have an IFD of 25, and the base layer might have an IFD of 30 (and the sculpted foam layer could be any one of the sleep support layer, the upper support layer, or the lower support layer, based on the configuration of the particular mattress). It should be notes that, typically, the base layer would not be the sculpted foam layer in disclosed embodiments (although other embodiments might have such positioning).

In some embodiments, one or more foam layer might be convoluted or channeled or have pin holes (for example, a plurality of vertical pin holes). Typically, such layers would not be either the base or the sculpted foam layers. It should be noted that the presence of convolutions/channels/pin holes may result in an effective IFD for the foam layer which is less than the actual IFD of the foam material (since removing material from the foam layer may cause the layer of foam to feel/perform as a softer foam). In such instances, the effective IFD of such foam layers might typically be set to be equivalent to the IFD of the foam of a solid/flat layer (e.g. without the removed material) in a similar position in the mattress embodiment.

FIGS. 1A and 2A illustrate two different embodiments of such a mattress 100/200. In both embodiments, the sleep surface 105/205 (e.g. the upper surface of the mattress) typically is a flat surface. In other words, the foam pillars (e.g. sculpted surface) do not form or serve as the sleep surface of the mattress 100/200. So in FIG. 1A for example, the sculpted layer of foam 110 is the upper layer of the mattress 100 forming the sleep surface (e.g. the sleep surface layer), and the layer of foam is oriented so that the sculpted surface (e.g. the pillars 112) projects/faces downward and the flat outer surface 115 of the integral base 114 forms the upper, sleep surface 105 of the mattress. FIG. 1Aa shows the mattress of FIG. 1A with the foam layers assembled (e.g. contacting and typically laminated). In some alternate embodiments, the sculpted foam layer 110 might be the uppermost support layer, and there could be one or more optional layers atop sculpted layer 110 (e.g. the sculpted layer might be the uppermost support layer of foam, with the one or more base and/or support layers underlying the sculpted layer, and no support layers located above the sculpted layer; rather, a sleep surface layer of foam might be located above the sculpted support foam layer). Typically in FIG. 1A, one or more layers might underlie the sleep surface layer of foam 110 (which here is the layer with a sculpted surface of foam pillars), serving as support and/or base layers for the mattress 100. For example, in FIG. 1A a middle/support (for example 3 inch) layer of foam 120 might directly underlie (and contact) the sleep surface layer of foam 110 (such that the extending pillars of foam would contact this middle layer), and a bottom/base layer of foam 130 might then underlie (and contact) the middle layer of foam 120 (with the bottom layer in the embodiment of FIG. 1A having a thickness of 6 inches for example). In FIG. 1A, the middle/support layer 120 would typically have an IFD less than that of the bottom/base layer 130 (although the two layers may have similar or identical foam density, for example about 1.8 pounds per cubic foot). So for example, the middle layer might have an IFD of 25 and the bottom layer might have an IFD of 33. The IFD of the sleep surface layer (which in FIG. 1A is the sculpted layer of foam) would typically be less than that of the middle/support layer of foam (with a specific example provided below for example). The underlying layer(s) of FIG. 1A (e.g. the layers of foam beneath/underlying the sculpted foam layer) would typically jointly be 5-11 inches thick or at least 9 inches thick (although additional thickness might be possible by having a greater thickness/height for one or more of the underlying layers or by having additional underlying layers of foam). Typically, the total height/thickness of the mattress 100 of FIG. 1A might be 8 to 14 inches, 12 inches or at least 12 inches (for example 12 to 15 inches). And typically, the sculpted layer of foam would have a sculpted surface in which the plurality of pillars of foam form substantially the entire sculpted surface (for example, with substantially the entire sculpted surface being divided up into pillars, which might typically be all equally sized and shaped in FIG. 1A as they cover the entirety of the sculpted surface of the sculpted foam layer). In other words, the grid of grooves of FIG. 1A forming the foam pillars would typically span the entirety (or substantially the entirety) of the sculpted surface of the sculpted foam layer.

FIG. 1B illustrates a similar embodiment (having the sculpted layer of foam 110 as the uppermost (sleep surface) layer of foam and being oriented with pillars extending downward), although the middle layer of FIG. 1B also may optionally include pin holes 122 (for example, due to hole punching) which may further improve airflow through the mattress and/or soften the feel of the mattress element, as described in U.S. patent application Ser. No. 14/471,689, hereby incorporated by reference with respect to pin holes to the extent not contradicting explicit disclosure herein. In FIG. 1B, the pin holes 122 are vertical (e.g. perpendicular to the surface of the foam layer), extending from the upper surface of the middle layer of foam 120 to the lower surface of the middle layer of foam 120 through the thickness/height of the layer of foam. In FIG. 1B, the vertical pin holes 122 might each have a diameter of about ⅛ inch to 1 inch, and would typically be spaced about 1-6 inches apart. FIG. 1Ba shows the mattress of FIG. 1B with the foam layers assembled (e.g. contacting and typically laminated).

FIG. 1C illustrates yet another embodiment similar to FIG. 1A above (having the sculpted layer of foam as the uppermost layer of foam and being oriented with pillars extending downward); however in FIG. 1C, the middle/support layer of foam 120 might optionally be convoluted, channeled (e.g. with channels extending across the mattress, as described in U.S. patent application Ser. No. 14/471,689, hereby incorporated by reference with respect to channels to the extent not contradicting explicit disclosure herein), or otherwise uniquely sculpted. For example, in FIG. 1C a plurality of channels 125 are formed (e.g. molded or cut) into the bottom surface of the middle/support foam layer, creating continuous open pathways extending across the width of the mattress. FIG. 1Ca shows the mattress of FIG. 1C with the foam layers assembled (e.g. contacting and typically laminated). As discussed above, the effective IFD of such a support layer might be set at the IFD level discussed above (for example, with the effective IFD of the middle/support layer being about 18-25).

The sleep surface layer of foam (e.g. the sculpted layer of foam) 110 in FIG. 1A would typically have a total thickness/height of 3 inches (although the height might range from 2-6 inches, 2-3 inches, 3-4 inches, etc. in some embodiments). Typically, the integrated base 114 of this sculpted foam layer 110 of FIG. 1A would typically span a third to a half of the total thickness of the sculpted layer of foam 110, while the height of the foam pillars 112 would typically represent the other half to two-thirds of the total thickness (e.g. in some embodiments the height/thickness of the foam pillars 112 might typically be approximately half the total thickness/height of the sculpted foam layer). In some embodiments, the sleep surface layer of foam 110 might be formed of gel memory foam. So typically in FIG. 1A, the sculpted sleep surface layer of foam 110 in FIG. 1A would be formed of a softer foam than used for any other layer of the mattress, might be formed of Gel Memory Foam, and/or might have an IFD of 10 to 20 and a density of 1.8 to 5.0 pounds per cubic foot. It should be noted that the contour cuts (e.g. grid of grooves or gaps forming the pillars in the sculpted surface of the sculpted foam layer) typically do not significantly impact IFD, such that the effective IFD for the sculpted foam layer would typically be approximately the same as the IFD for the foam forming the layer (and any minimal difference would be with the effective IFD of the sculpted foam layer being just below the IFD of the foam). In FIG. 1A, the sleep surface layer of foam 110 would have grooves or gaps 117 separating the pillars 112 (as shown in FIG. 3 for example), and each such gap might typically be ⅜-1 inch wide and 1-2 inches deep (for example, in the embodiment of FIG. 1A the grooves 117 would typically be ⅜ of an inch wide and 1½ inches deep). Furthermore, the pillars of foam 112 in this embodiment would typically each have square cross-section (although in other embodiments, the horizontal cross-section could be another type of rectangle or even some other formed shape, such as a circle, triangle, hexagon, etc). So for example, the outer/distal surface (and cross-section) of each pillar 112 might be 3 and ⅝ inches by 3 and ⅝ inches in some embodiments. In other embodiments, the outer/distal surface (and cross-section) of each pillar 112 might instead be 4 and ⅝ inches by 4 and ⅝ inches. So typically, each of the cross-section dimensions of each pillar might vary from 3 and ⅝ inch-4 and ⅝ inch. In other embodiments, each of the cross-section dimensions of each pillar might range from 2-6 inches (and while in the embodiment of FIG. 1A all pillars have the same size/cross-section and shape, in other embodiments the pillar size/shape might vary). Persons of skill in the art will understand that the height of the pillars 112, as well as the cross-sectional size/area of the pillars, might vary depending on the desired mattress feel (although the plurality of pillars are typically uniform in size and shape in the embodiment of FIG. 1A; in other embodiments, however, the size of the pillars (for example the cross-section) could be non-uniform/vary). In some embodiments, the depth/height of the grooves might also vary between pillars (e.g. not all pillars would be the same height in such embodiments). In FIG. 1A, the entire sculpted surface would be divided into a plurality of equally sized pillars (e.g. the grid of grooves would cover the entire lower surface), but other alternative embodiments might have pillars on only a portion of the sculpted surface of the sculpted layer of foam.

In the embodiment of FIG. 1A, the mattress 100 is an all foam mattress (without coil springs for example). In other words, the mattress of FIG. 1A (and all embodiments shown in the included figures) is spring-free and has a sculpted layer of foam with a plurality of independent foam pillars (which might be termed foam springs). And some embodiments may also have one or more layers (which might typically be latex or gel memory foam, but could also include any type of foam) located above all of the support foam layers (for example, the three layers of foam shown in FIGS. 1A-1D). The foam layers for the mattress embodiments (for example the foam layers 110, 120, 130 in FIG. 1A) would typically be enclosed/encased within a cover (not shown). In some embodiments, the cover might also include one or more mesh panels along one or more of its sides, in order to improve cross-sectional airflow through the mattress (especially given the air flow potential between the foam pillars). Such a cover with mesh panels is described in U.S. patent application Ser. No. 14/471,689, hereby incorporated by reference with respect to the cover to the extent it does not contradict explicit disclosure herein. In such embodiments, the mesh panels would typically be located at a height corresponding to that of at least a portion of the pillar portion of the sculpted foam layer (e.g. so that the panels might align with at least a portion of the pillar portion of the sculpted foam layer to allow improved air flow through the mattress). In other embodiments, such as FIG. 1C, the mesh panels might be positioned/oriented to correspond to at least a portion of the channels. Given the position and orientation of the sleep surface sculpted layer of foam 110 in FIG. 1A (e.g. serving as the top layer, with pillars oriented downward), the upper surface 105 of the mattress of FIG. 1A would be flat, forming a continuous sleep surface for contact with any user lying atop the mattress. Of course in other embodiments similar to FIG. 1A, there could also be additional foam layers located atop the layer of foam with sculpted surface (e.g. the layer with pillars). For example, as shown in FIG. 1D, there could be an additional sleep surface layer of latex, gel memory foam, memory foam, or other foam located above (and typically in direct contact with) the sculpted foam layer (and the sculpted support layer of foam would be oriented with pillars facing downward). Thus, FIG. 1D might have the sculpted foam layer 110 as the middle/support layer, located between a sleep surface layer 140 (which is a flat sheet of foam in this embodiment) and a base layer 130 of foam. FIG. 1Da shows the mattress of FIG. 1D with the foam layers assembled (e.g. contacting and typically laminated). In some embodiments, this top foam layer of FIG. 1D might optionally be hole punched or otherwise formed with vertical pin holes (as described in more detail with respect to FIG. 4 for example). In such a layer (with pinholes), the effective IFD for this sleep surface layer would typically be equivalent to the preferred IFD for the foam of a solid layer (for example, the effective IFD might be 10-20, perhaps 12 for example). And while there could be multiple layers of foam underlying the sculpted foam layer, in FIG. 1D only a single bottom/base layer underlies the sculpted foam layer.

Some mattress embodiments might have four layers of foam (for example, with two support layers underlying a top sculpted sleep support layer in conjunction with a base layer, or a flat sleep surface layer atop a sculpted support layer, which is underlain by an additional support layer and a base layer). FIG. 1E illustrates one exemplary embodiment of such a four layer foam mattress.

FIG. 2A illustrates an alternative embodiment mattress 200 in which the sculpted layer of foam 210 (e.g. the contour cut foam layer or the foam layer having pillars) is located and oriented differently. In this embodiment, the sculpted layer of foam 210 (with pillars) is not the top layer of the mattress 200 (or in some embodiments, it is not the top support layer of the mattress), but instead is located underneath an upper, sleep surface layer of foam 250 (which might be latex or some other foam). Typically in this embodiment, the sculpted layer of foam 210 would be oriented so that the foam pillars 212 extend upward, with the outer (flat) surface 215 of the integrated base 214 facing downward. In other words, the sculpted layer of FIG. 2A would typically be oriented with the sculpted surface facing upward. Typically, the sculpted layer of foam 210 in the embodiment of FIG. 2A would have similar dimensions and/or be similarly formed as discussed above with respect to FIG. 1A (for example, this sculpted layer of foam might be shaped identically regardless of orientation and placement within the mattress of FIG. 1A or 2A, having the same integral base portion and pillar portion, although the placement of the sculpted foam layer with respect to the other layers may affect the IFD of the foam selected (for example, depending upon whether the sculpted foam layer is a sleep surface layer or a support layer)). For example, the sculpted layer of foam of FIG. 2A would typically have a sculpted surface in which the plurality of pillars of foam form substantially the entire sculpted surface (for example, with substantially the entire sculpted surface being divided up into pillars, which might typically be all equally sized and shaped in FIG. 2A as they cover the entirety of the sculpted surface of the sculpted foam layer). In other words, the grid of grooves of FIG. 2A forming the foam pillars would typically span the entirety (or substantially the entirety) of the sculpted surface of the sculpted foam layer.

So in FIG. 2A, the upper, sleep surface layer of foam 250 might typically be either a gel memory foam or latex foam sleep surface, for example uniformly 3 inches thick (with a flat upper sleep surface 205 and a flat bottom/opposing surface). The upper layer of foam 250 in FIG. 2A might typically be gel memory foam (for example, with density of 1.8 to 5.0 pounds per cubic foot and IFD from 10-20) or latex foam (for example with density of 2.5 to 6.0 pounds per cubic foot and IFD of 8 to 20. The sculpted foam layer 210 might then form the middle/support layer (or one of a plurality of inner/support layers) of the mattress (and might typically have a total thickness of 3 inches). This middle (or inner) sculpted foam layer 210 might be formed of conventional foam in this embodiment (for example, similar to that of the middle layer in the embodiment of FIG. 1A). For example, the middle sculpted foam layer 210 might be formed of polyurethane foam with density of 1.8 and IFD of 20). Alternatively, the sculpted foam layer might be formed of gel memory foam, latex, or some other foam material. The bottom base layer of foam 230 in FIG. 2A might then have a thickness of 6 inches (or more), and typically would be similar to that discussed above with respect to FIG. 1A.

Since the sculpted (e.g. contour cut) layer of foam 210 in FIG. 2A is oriented with the pillars 212 facing upward, this sculpted foam layer 210 would be located beneath one or more flat layers of foam 250 (so that the upper surface layer of foam might form a continuous (e.g. unbroken/non-segmented/flat) sleep surface 205, for example). FIG. 2B illustrates a similar embodiment from an exploded cut-away perspective view. FIG. 2Ba shows the mattress of FIG. 2B with the foam layers assembled (e.g. contacting and typically laminated). It should be noted that in some embodiments (similar to FIGS. 2A-B), the top layer of foam located directly above the sculpted foam layer might be hole punched or otherwise formed with vertical pin holes (for example, extending through the thickness/height of the layer). Such an alternate embodiment is shown in FIG. 2C.

FIG. 2D shows a four foam layer mattress embodiment, with two layers of foam (a sleep surface layer 250 and an upper support layer 240) located above the sculpted (support) foam layer 210, and a bottom, base layer of foam 230 underlying the sculpted foam layer. Other positions for the sculpted foam layer in alternate four layer mattress embodiments are possible. For example, in an alternate embodiment, a flat sleep surface layer of foam might be located directly above (and contacting) the sculpted foam layer (which would be the upper support layer), and there might be a lower support layer and a base layer underlying the sculpted foam layer. The IFD of the sculpted foam layer might vary, depending for example, on the location of the sculpted foam layer with respect to the other layers (as discussed above).

In both FIGS. 1A and 2A (and similar embodiments), the foam pillars 112/212 of the sculpted foam layer 110/210 may act as a series of independent foam springs. In this way, they may allow the mattress to better conform to any user lying atop the sleep surface of the mattress. For example, the independent nature of the foam pillars (e.g. separated by a groove and/or linked at their bases only by a foam base and/or adhered to the adjacent layer of foam in a manner that does not introduce torsion and/or shear forces during construction) may allow for independent (and typically primarily vertical) movement of each foam pillar, thereby reducing pressure points. Thus, the foam pillars may enhance support and comfort, providing improved mattress experience (for example, compared to metal springs in conventional mattresses, which typically may not move/behave in the same manner as the foam pillars of the all-foam mattress embodiments described above).

And as noted above, the foam sleep support layers of the mattress might typically be enclosed within a cover, which optionally may include one or more mesh panels (or other means for allowing airflow through the cover) on one or more sides of the mattress. Typically when the cover includes such mesh panels, there might be matching/corresponding mesh panels on opposite sides of the mattress to help enhance airflow through the mattress. Such optional mesh panels would typically be positioned and/or oriented to improve airflow with respect to the grooves of the sculpted foam layer and/or any channels or convolutions in other foam layers.

FIG. 3 is a plan view of an exemplary sculpted (e.g. contour cut) layer of foam 110 showing the sculpted surface with the pillars projecting outward (for example as seen in FIGS. 1A and 2A), and showing that the plurality of foam pillars 112 are each separated from one another (e.g. from the surrounding pillars) by one or more gap or groove 117. The series of grooves in FIG. 3 form a grid or checkerboard pattern of pillars. In FIG. 3, the cross-sectional size and depth of the foam pillars are uniform (e.g. all of the pillars have the same dimensions). In other embodiments, however, the cross-sectional size and depth of the foam pillars could be varied, depending on the needs of particular mattress. So while typically each of the foam pillars would be identically sized, in other embodiments there may be some variation in size of the foam pillars (for example different zones of the mattress might have different pillar sizes). Additionally, each of the pillars of FIGS. 1-3 has a uniform horizontal cross-section along their height (e.g. the pillars are rectangular blocks), but in other embodiments each of the pillars might have a cross-section that varies along height (for example, they might each be pyramidal, with a broader base than top). Persons of skill will understand such variation, all of which is intended to be included with the scope of the present disclosure. FIG. 4 illustrates an exemplary non-sculpted foam layer that has been hole punched (or formed with pin holes), as described above optionally with respect to FIGS. 1B and/or 2C. In this example, each pinhole would typically have a diameter of about ⅛-1 inch, and the pinholes might be spaced about 1-6 inches apart.

In forming the mattress of FIG. 1A, a sculpted layer of foam would be provided, along with the one or more underlying (e.g. base) layers of foam (and typically a cover). Providing a sculpted layer of foam might comprise forming the sculpted layer of foam. While the sculpted layer of foam might be formed via molding, typically the pillars are cut into a surface of a (typically uniform thickness) foam sheet (forming a contour cut grid pattern that extends part of the way through the depth of the foam sheet to form a plurality of independent foam pillars or blocks). For example, the grid pattern forming the pillars might typically be cut by means of a computer controlled machine with a fine cutting blade. In other words, a series or pattern (e.g. grid) of gaps are grooves might be cut into one of the surfaces of the foam sheet, to form the sculpted layer of foam having a plurality of foam pillars (in the pillar portion) extending out from an integral base portion (which would not include such grooves, but would join all pillars together into a unified whole layer). The sculpted layer of foam might typically be contour cut from a single piece/sheet of foam. Typically, such grooves would only be cut down through about half the height of the foam sheet (leaving a unified base portion without grooves). The type of foam, density of foam, and IFD for each layer of foam might also be selected based on the specific needs or desired characteristics of the mattress. For example, the top (sleep surface) layer might be selected to be gel memory foam (e.g. so the sculpted layer might be formed of gel memory foam if, for example, the sculpted layer forms the top sleep surface layer). If the sculpted layer is not the uppermost (e.g. sleep surface) layer, however, it might be selected as some other (non-gel memory foam) type of foam, for example conventional foam, while the uppermost (e.g. sleep surface) layer might then be selected to be gel memory foam or latex foam. And typically, the foam characteristics (and/or type) might be selected based on the position of the foam layer with respect to the other foam layers in the mattress (for example, based on whether the foam layer is a sleep surface layer, a support layer, or a base layer). Once the sculpted layer of foam has been provided, it can be positioned/oriented with respect to the other layers of foam. Typically, the sculpted layer might be laid flat with the sculpted surface (e.g. pillars) facing upward. Then, the layer of foam (e.g. the layer of foam which will underlie the sculpted foam layer of FIG. 1A) which is to contact the sculpted surface of the sculpted layer would be positioned precisely above (but not yet contacting) the sculpted layer (e.g. aligned) and then lowered vertically (and typically only vertically) into contact with the sculpted surface. Such precise movement/placing of the foam layer with respect to the sculpted surface of the sculpted layer may ensure that there is no horizontal/sideways movement when placing/positioning/orienting the foam layers together into contact, thereby preventing the introduction of any shear or torsion forces into the foam pillars of the sculpted surface of the sculpted layer of foam during construction. The layers might then be flipped/reoriented so the foam pillars project in the desired direction depending on the embodiment (for example, the foam pillars directing downward in FIG. 1A embodiment). Typically, the foam layers would also be adhered/laminated to each other to form an integral whole. So for example, adhesive might be applied to one surface of the foam layer which is to contact the sculpted surface of the sculpted foam layer, before that foam layer is lowered into contact with the sculpted surface (e.g. pillars) of the sculpted foam layer. And typically, each of the foam pillars of the sculpted layer of foam would be oriented in the same way and/or loaded (for example, only in compression) in the same way once the mattress is assembled (but prior to usage—e.g. when there is nothing atop the mattress). This may allow each of the foam pillars to perform under loading in the same manner (e.g. if an identical load is applied to any one of the foam pillars on a sculpted foam layer, it would behave in the same manner (e.g. movement) as any other foam pillar in the sculpted foam layer under the same loading conditions). And typically, the distal surface of each foam pillar in the sculpted foam layer would tend to remain substantially horizontal during deformation when a load is applied to the mattress surface atop the foam pillar (since, for example, the distal surfaces of the foam pillars would not be linked together by a rigid wire element, as in traditional coil spring mattresses). In some alternate embodiments, the foam layers may not be adhered/laminated (or otherwise joined) together, and/or at least the sculpted surface may not be joined to any adjacent layer of foam (which might further alter the foam pillar movement, for example to maintain the distal surface of the foam pillar horizontally during deformation). The layers of foam can also be enclosed within a cover. So for example for the mattress in FIG. 1A, the sculpted layer of foam would be oriented with the pillars facing downward and would be the topmost (uppermost) layer of foam within the mattress (which typically is an all foam mattress without any springs). The middle support layer of foam would typically have an IFD less than that of the bottom support layer of foam. In some embodiments, the cover might include one or more mesh panels (for example located in one or more of the sides of the cover). In such embodiments, providing the cover might include forming the cover, wherein the cover comprises the one or more mesh panels.

In forming the mattress of FIG. 2A, once again the sculpted layer of foam would be provided, along with one or more base layers of foam and an upper surface layer of foam (which would form the sleep surface of the mattress). The sculpted layer of foam might be formed in a similar manner described above (e.g. selecting foam and molding or cutting a pattern or grid of grooves or gaps to form the plurality of pillars in the sculpted layer of foam). A cover might also be provided for enclosing the foam support layers. Typically for the mattress of FIG. 2, the sculpted layer of foam would be oriented with the pillars facing upward, and the sculpted layer of foam would be located beneath the upper surface layer of foam but above the base layer of foam. And as described above, the layers of foam might be laminated together (for example, with the layer above the sculpted layer in FIG. 2A being lowered atop the pillars of the sculpted foam layer, for example after adhesive is applied to the contacting/lower surface). The cover for FIG. 2A might be formed a similar manner described above, and would enclose or encase the upper surface layer, the sculpted layer, and the base layer of foam to form the mattress. So, formation of the mattress of FIG. 2A might be quite similar to the method described above for FIG. 1A, except for location/position of the sculpted layer, orientation of the sculpted layer, and perhaps selection of the foam material. And again, the type of foam, density of foam, and IFD for each layer of foam might also be selected based on the specific needs or desired characteristics of the mattress. For example, the upper sleep surface layer of foam might be selected as gel memory foam or latex, while the sculpted layer of foam might be selected as conventional foam (or some other foam) in some embodiments. Typically, the foam layers would be adhered/laminated together (similar to the discussion above). As noted above, embodiments of FIGS. 1A and 2A are both all-foam and/or spring-free mattresses, which would not include coil (or other) springs (e.g. metal springs) within the cover. The gaps or grooves in these embodiments typically extend uniformly throughout their depth, such that each of the pillars would be rectangular in shape. The width and depth of the grooves could be selected based on the needs of the mattress (but typically might penetrate down through about half, at least half, or ¼ to ⅔ the height/thickness of the sculpted layer of foam, leaving a base portion without any grooves). Additionally, the size and shape (and number) of the pillars might be selected based on the needs of the mattress. The position and orientation of the sculpted layer of foam would provide a flat sleep surface for the user to lie atop, while also enhancing the support and/or comfort of the mattress. FIG. 5 illustrates graphically an exemplary method of formation similar to those described above, for a mattress embodiment similar to that of FIG. 1A.

While various embodiments in accordance with the principles disclosed herein have been shown and described above, modifications thereof may be made by one skilled in the art without departing from the spirit and the teachings of the disclosure. The embodiments described herein are representative only and are not intended to be limiting. Many variations, combinations, and modifications are possible and are within the scope of the disclosure. Alternative embodiments that result from combining, integrating, and/or omitting features of the embodiment(s) are also within the scope of the disclosure. Accordingly, the scope of protection is not limited by the description set out above, but is defined by the claims which follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated as further disclosure into the specification and the claims are embodiment(s) of the present invention(s). Furthermore, any advantages and features described above may relate to specific embodiments, but shall not limit the application of such issued claims to processes and structures accomplishing any or all of the above advantages or having any or all of the above features.

Additionally, the section headings used herein are provided for consistency with the suggestions under 37 C.F.R. 1.77 or to otherwise provide organizational cues. These headings shall not limit or characterize the invention(s) set out in any claims that may issue from this disclosure. Specifically and by way of example, although the headings might refer to a “Field,” the claims should not be limited by the language chosen under this heading to describe the so-called field. Further, a description of a technology in the “Background” is not to be construed as an admission that certain technology is prior art to any invention(s) in this disclosure. Neither is the “Summary” to be considered as a limiting characterization of the invention(s) set forth in issued claims. Furthermore, any reference in this disclosure to “invention” in the singular should not be used to argue that there is only a single point of novelty in this disclosure. Multiple inventions may be set forth according to the limitations of the multiple claims issuing from this disclosure, and such claims accordingly define the invention(s), and their equivalents, that are protected thereby. In all instances, the scope of the claims shall be considered on their own merits in light of this disclosure, but should not be constrained by the headings set forth herein.

Use of broader terms such as comprises, includes, and having should be understood to provide support for narrower terms such as consisting of, consisting essentially of, and comprised substantially of Use of the term “optionally,” “may,” “might,” “possibly,” and the like with respect to any element of an embodiment means that the element is not required, or alternatively, the element is required, both alternatives being within the scope of the embodiment(s). Also, references to examples are merely provided for illustrative purposes, and are not intended to be exclusive.

While several embodiments have been provided in the present disclosure, it should be understood that the disclosed systems and methods may be embodied in many other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered as illustrative and not restrictive, and the intention is not to be limited to the details given herein. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted or not implemented.

Also, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other systems, modules, techniques, or methods without departing from the scope of the present disclosure. Other items shown or discussed as directly coupled or communicating with each other may be indirectly coupled or communicating through some interface, device, or intermediate component, whether electrically, mechanically, or otherwise. Other examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the spirit and scope disclosed herein. 

What is claimed is:
 1. A mattress comprising a sculpted foam layer with a sculpted surface having a grid pattern of grooves thereon forming a plurality of foam pillars projecting outward from a common, integral base of foam; wherein the sculpted surface with the grid pattern of grooves is not the mattress sleep surface; and wherein the mattress does not include springs.
 2. The mattress of claim 1 wherein the sculpted foam layer comprises an integral base portion of uniform thickness and a pillar portion comprising the plurality of independent foam pillars separated from each other by one or more grooves of the grid pattern; and wherein a surface of the sculpted foam layer opposite the sculpted surface is substantially flat.
 3. The mattress of claim 1 further comprising a cover, and wherein the mattress is an all-foam mattress.
 4. The mattress of claim 3 further comprising one or more additional layers of foam underlying the sculpted foam layer.
 5. The mattress of claim 4 wherein the sculpted foam layer is located as the uppermost layer of foam within the mattress and is oriented with the sculpted surface having the grid of grooves facing downward.
 6. The mattress of claim 1 further comprising an upper foam layer, and wherein the sculpted foam layer is located beneath the upper foam layer and is oriented so that the sculpted surface having the grid of grooves faces upward.
 7. The mattress of claim 6 further comprising a base foam layer underlying the sculpted foam layer, wherein the upper foam layer has a uniform thickness and has a flat upper surface.
 8. The mattress of claim 1 further comprising at least one additional layer of foam, wherein the uppermost foam layer is formed of gel memory foam or latex.
 9. The mattress of claim 1 wherein the grooves in the sculpted layer of foam are about ⅜-1 inch wide and about 1-2 inches deep.
 10. The mattress of claim 1 wherein the plurality of foam pillars in the sculpted foam layer are each uniform in size and shape.
 11. The mattress of claim 1 wherein each of the plurality of foam pillars have a rectangular cross-section.
 12. The mattress of claim 10 wherein each of the plurality of foam pillars have horizontal cross-section sides each ranging from 2-6 inches.
 13. The mattress of claim 10 wherein each of the plurality of foam pillars have a rectangular cross-section, and wherein each of the plurality of pillars of foam have cross-section sides each ranging from about 3 and ⅝ inches to about 4 and ⅝ inches.
 14. The mattress of claim 3 wherein the cover comprises one or more mesh panels located to improve airflow through the grooves in the sculpted layer of foam.
 15. The mattress of claim 1 wherein the sculpted foam layer has a thickness of 2-4 inches.
 16. The mattress of claim 1 wherein the sculpted foam layer has a thickness of about 2-4 inches, and wherein the grooves in the sculpted foam layer are about ⅜-1 inch wide and extend downward through about half to two-thirds of the total thickness of the sculpted foam layer.
 17. A mattress comprising: a sculpted foam layer with a sculpted surface having a grid pattern of grooves thereon forming a plurality of foam pillars projecting outward from a common, integral base of foam; one or more additional layers of foam underlying the sculpted foam layer; and a cover; wherein the sculpted foam layer is located within the mattress above the one or more additional layers of foam and is oriented with the sculpted surface having the grid of grooves facing downward; wherein a surface of the sculpted foam layer opposite the sculpted surface is substantially flat; wherein the sculpted surface with the grid pattern of grooves is not the mattress sleep surface; wherein the foam layers are all laminated together into an integrated whole; and wherein the mattress does not include springs.
 18. The mattress of claim 17 wherein the sculpted foam layer is formed of gel memory foam, and wherein the cover comprises one or more mesh panels located to improve airflow through the grooves in the sculpted layer of foam.
 19. The mattress of claim 17 wherein the plurality of foam pillars in the sculpted foam layer are each uniform in size and shape and each have a rectangular cross-section; and wherein the flat surface of the sculpted foam layer opposite the sculpted surface faces upward to serve as a sleep surface for the mattress.
 20. The mattress of claim 19 wherein each of the foam pillars have a square cross-section, and wherein each of the plurality of foam pillars have cross-section sides ranging from about 3 and ⅝ inches to about 4 and ⅝ inches. 